Method and apparatus for making plastic

ABSTRACT

Shaped gusset bags of heavy gauge material are made by separately welding a generally V-shaped notch in the top and bottom sections of the gusset, providing a short slit in the notches, providing pairs of transverse seam welds which intersect the notch welds, and then cutting along the notch welds and between the transverse seam welds. In another embodiment, the notch is welded and cut out at one station and then moved to a second station wherein the material is cut and welded transversely.

United States Patent [72] inventor Francis A. Davis Jr. [56] ReferencesCited Lansdale- UNITED STATES PATENTS QE A- 2,2 1968 3,023,679 3/1962Piazze 93/35x i 3 395,622 8 1968 K I 9 3 45 Patented Jan. 19, 1971 er 3/5 [73] Assignee Paramount Packaging Corporation Primary Examiner-BernardStrckney Chalfont, Pa. Attorney-Seidel and Gonda a corporation ofDelaware ABSTRACT: Shaped gusset bags of heavy gauge material are madeby separately welding a generally V-shaped notch in the [54] METHOD ANDAPPARATUS FOR MAKING top and bottom sections of the gusset, providing ashort slit in PLAS TIC BAGS the notches, providing pairs of transverseseam welds which 9 Chums l4 Drawmg intersect the notch welds, and thencutting along the notch [52] US. Cl. 93/8, 93/35 welds and between thetransverse seam welds. In another em- [5 1] Int. Cl B31b 1/00 bodiment,the notch is welded and cut out at one station and [50] Field of Search93/8, 35, then moved to a second station wherein the material is cut and35(lnquired) welded transversely.

3.555.974 3am 1 UFS 1 'PATENIEDIJMQIIIQII INVENTOR FRANCIS A. DAV/.5,JR.

PAjEN-IEDJAMQIQI sum u 0? 5 INVENTOI? FRA/vc/s A. DAVIS, JR.

saw/M ATTORNEYS SHEET 5 0F 5 INVENTOR FRANCIS A. DAVIS; JR.

ATTORNE Y5 1 METHOD AND APPARATUS FOR MAKING PLASTIC BAGS This inventionrelates to a method andapparatus for making bags similar to thatdisclosed in US. Pat. No. 3,282,173. The machine in that patentmanufactures open gusset bottom bags having square corners. The presentinvention is directed to method and apparatus for making modified orshaped gusset bags having beveled or rounded comers. Modified or shapedgusset bags are desirable since they enable the bag to more closelyconform to the shape of the article placed therein. For example, when around object is placed in a square bag, the object is permitted to movein the bag and a substantial portion of the bag is unused.

The present invention accomplishes the object of making modified orshaped bottom gusset bags in a manner which is simple, reliable,inexpensive, and lends itself to high speed production rates. Inpracticing the present invention, generally V-shaped seam welds areintermittently provided at the fold line of thermoplastic sheetmaterial. If the notch had not been previously cut out, subsequentoperations include effecting a transverse seam weld at the apex of eachnotch and then cutting the notch and along a transverse line between theseam welds.

In order to prevent the four layers of material at the gusset from beingwelded together, it is conventional to apply a layer of heat resistantink, shellac or other material to the gusset. The present invention isparticularly designed to make bags which are not suited to having such aheat resistant layer or bags on which it is desired that no such heatresistant layer be used. Prevention of welding all four layers of thegusset from being welded is accomplished by dividing the gusset into topand bottom sections which are simultaneously first seam welded and thennotched. Welding and then notching is accomplished using equipmentsimilar to that disclosed in U.S. Pat. No. 3,384,528.

When cutting notches in the thermoplastic material, a small generallytriangular-shaped tab is produced. The thinness of the material which iscommercially used and the large amount of static electricity involvedtherewith, tends to cause the tabs to stick to various parts of themachinery and accumulate in a manner which interferes with properfunctioning of the machinery. Hence, a positive means is provided toremove the cutout tab.

It is an object of the present invention to provide novel method andapparatus for making a modified bottom gusset bag.

It is another object of the present invention to provide novel apparatusand method for making a modified bottom gusset bag of thermoplasticmaterial in a manner which is simple, reliable, and lends itself to highspeed production.

Other objects will appear hereinafter.

For the purpose of illustrating the invention, there is shown in thedrawings a form which is presently preferred; it being understood,however, that this invention is not limited to the precise arrangementsand instrumentalities shown.

FIG. 1 is a top plan view of the apparatus of the present invention.

FIG. 2 is a partial perspective view of the apparatus in FIG.

1 on an enlarged scale.

FIG. 3 is a sectional detail view taken along the line 3-3 FIG. 1.

FIG. 4 is a perspective view of the tab.

FIG. 5 is a partial plan view taken along the line 5-5 in FIG.

FIG. 6 is a sectional view taken along the line 6-6 in FIG. 2. FIG. 7 isa plan view of the transverse seam welder, anvil and cutter.

FIG. 8 is a partial plan view of the seam welds and cuts made betweentwo adjacent bags.

FIG. 9 is a sectional view taken along line 9-9 in FIG. 6.

FIG. 10 is a view similar to FIG. 3 but illustrating another embodiment.

FIG. 11 is a bottom view taken along the line 11-11 in FIG.

FIG. 12 is a plan view taken along the line 12-12 in FIG. 10.

FIG. 13 is a partial perspective view of transverse welding and slittingapparatus to be used in conjunction with the structure in FIG. 10.

FIG. 14 is a sectional view taken along the line 14-14 in FIG. 13.

Referring now to the drawings in detail wherein like numerals indicatelike elements, there is shown a bag making machine of the presentinvention designated generally as 10. The machine 10 is intended to havefed therethrough a pair of spaced parallel thermoplastic webs l2 and 14.Thus, the machine 10 has two parallel production lines, each defined byone of the webs. The webs 12 and 14 are folded-over sheets ofthermoplastic material having a single fold line 16 and 18 respectively.Along the length of the webs, there is printed markers for breaking thebeam of photocell units which intermittently operate the machine 10.

Since each of the webs 12 and 14 are treated in the same manner, onlyweb 12 will be described in detail. It will be understood that thecorresponding structure illustrated is utilized in conjunction with web14. From large rolls, the web 12 is unwound and fed through a takeuproll assembly 24 in a folded manner so as to have a top layer 20 and abottom layer 22 connected together along the fold line 16. From theassembly 24, a bottom gusset is provided by the plate 26. A similarplate 28 is provided for web 14. The gusset plates 26 and 28 may be ofthe type as shown in the above-mentioned U.S. Pat. No. 3,282,173.

The gusseted web 12 is then fed in a manner so that a protruding lip oredge portion 29 is provided as shown in the above-mentioned patent sothat perforations or slits may be provided by the slitter 30. A similarslitter 32 is provided for web 14. The slitter may be of the type shownin U.S. Pat. No. 3,183,750 which is useful for producing bags of thetype shown in U.S. Pat. No. 3,184,055.

Thereafter, the webs are fed to intermittently operated notch welders 34and 36 respectively. The welders 34 and 36 provide discrete notchesdefined by seam welds 37, 39 and 41 at spaced points along the length ofthe fold line 16. The notches are made separately in the top section 38and bottom section 40 of the gusset as shown more clearly in FIG. 3. Awater-cooled anvil 42, which is generally V-shaped in cross section, isprovided. Top section 38 is comprised of layers 44 and 46 which overliethe top surface 43 of anvil 42. Bottom section 40 is comprised of layers48 and, 50 which overlie the bottom surface 45 of anvil 42. Surfaces 43and 45 are defined by a layer of Teflon 47 having a rubber padundercoating 49. The layer of Teflon 47 prevents the sections 38 and 40from sticking to the anvil 42.

Seam welds 37 and 39 are made in top section 38 by a V- shaped seamwelder 52 carrying a knife 54. Knife 54 cuts slit 56 while the seamwelds are made. Seams welds 37 and 39 are made in the bottom section 40by a V-shaped seam welder 58 carrying a knife 60. Knife 60 performs thesame function as knife 54in the same manner. The welders 52 and 58 aresimultaneously reciprocated in a direction perpendicular to surfaces 43and 45, respectively, by piston and cylinders.

Thereafter, the webs 12 and 14 are fed to intermittent transverse seamwelder-cutters 62 and 64, respectively. Each of the welder-cutters 62and 64 provide a pair of seam welds defining a side edge of the bag andwhich intersects with the weld 41.

As shown more clearly in FIGS. 7 and 9, the welder-cutter 62 includes aplate-like support 66 having electrically heated, spaced, parallelwelding jaws 68 and 70. A cutting blade 72 is disposed between and islonger than anvil jaws 67 and 69. Anvil jaw 67 has an extension 67 and amating portion 67 between which is located a blade 76. Anvil jaw 69 hasan extension 69' and a mating portion 69" between which is located ablade 74. Blades 74 and 76 on support 66 do not touch blade 72 butcooperate with blade 72 to form a disconnected Y-shaped cutting bladestructure of sufficient length to extend transversely across the web 12.Welding jaws 68 and 70 have extensions so as to be Y-shaped forcooperation with the Y-shaped anvil. However, the extensions'on weldingjaws 68 and 70 are not heated by heater 71 as illustrated in FIG. 6.

The welder-cutter 62 includes uprights 78 and 80 connected,respectively, to frame portions. The uprights'are connected together bya crossbar 82 which supports a cylinder 84.

The piston rod 86 projecting downwardly from the cylinder 84 isconnected to the top of a holder 88 to which is secured support 66.

Since the converging blades 74 and 76 on the support 66 extend acrossthe gusset, every time a cut is made transversely across the web, atriangular tab 96 is produced by said legs. See FIG. 4. A tab removerdesignated generally as 97 is synchronized and cooperatively disposedwith the weldercutter 62. The tab removed 97 includes a cylinder 98having its piston rod 99 connected to a clevis at one end of an arm 100.Arm 100 is pivotably supported intermediate its ends. The end of arm 100remote from the clevis is pivotably coupled to one end of a shuttle 102.Shuttle 102 extends through a spring housing 104 having a spring thereinbiasing the shuttle in a counterclockwise direction in FIG. 2. Theshuttle 100 at its other end terminates in a sharp point and adjacentthereto has an enlargement for contact with the plate 55 which extendsbetween the portion 67" and 69" supported by support 66.

A conduit 106 is provided for receiving the V-Shaped tab 96. A conduit108 is provided for receiving the V-shaped tab from the web 14. Conduits106 and 108 each communicate with the inlet to a vacuum pump 110 mountedon a hollow drum 112 into which the tabs may be introduced from theoutlet of the vacuum pump 110. A shre'dder may be provided in the drum112 for shredding the tabs. A conveyor 114 is provided as shown moreclearly in FIG. 2 to receive the open gusset bottom side welded bags 116and convey the same away from the apparatus 10.

The operation of the apparatus is as follows:

Webs 12 and 14 are continuously fed from rolls to the machine 10. Thewebs are intermittently moved along machine 10. Marks on the webs aredetected by the photocell units which interrupt motor 94. The webs arecontinuously folded and shaped so as to provide a gusset at their foldlines with the webs being in the form of overlapping layers.

Each time that the web 12 is stationary, the perforator unit providesslits in the lip 29. Also, when the web 12 is stationary, motive fluidwill be introduced into cylinder 84 to move the support 66 downwardly tosimultaneously cut the web 12 transversely and effect a pair of spacedside welds to the cut portions of the web 12 as will be explainedhereinafter. Each time the web is stationary, the welders 52 and 58reciprocate toward the anvil 42 to form the V-shaped welds 37, 39 and 41in each of the sections 38 and 40. Also, slits 56 are formed at the sametime by knives 54 and 60.

When the support 66 moves downwardly, motive fluid is simultaneouslyintroduced into the cylinder 98 which causes the arm 100 to move theshuttle 102 inwardly so that the free end of shuttle 102 is below thesupport 66. As the support 66 continues to move downwardly, it contactsthe enlarged portion on the terminal end of shuttle 102 and moves itdownwardly so that the point on the shuttle 102 digs into the gussetedportion of the web 12 at a location which will be part of the triangularshaped tab 96 cut by the blades 74 and 76. While the shuttle 102 pivotsin a clockwise direction in FIG. 2 due to contact with the support 66,the spring in housing 104 is compressed slightly.

When the jaws 68 and 70 engage the web 12, welds 87 and 89.respectively, are formed as shown in FIG. 8. Welds 87 and 89 eachoverlap one end of weld 41. At the same time, knife .72 slits the web 12along line 73 which intersects slit 56. Also, knife blade 74 slits thenotch along line 75which intersects slit 56 and knife blade 76 slits thenotch along line 77 which intersects slit 56.

As soon as the web 12 commences to move again, motive fluid isintroduced into cylinder 84 to retract the support 66 and motive fluidis introduced into cylinder 98 to retract the shuttle 102. As theshuttle 102 retracts, it pulls the triangular shaped tab 96 into theconduit 106 in which a suction is effected by way of pump 110. Pump 110discharges the tab 90 into tank 112. Conveyor 114 transports the bag 116to a stacking area.

The use of a pair of welders to separately form the notch defined bywelds 37, 39 and 41 in each of the gusset sections 38 and 40 enablesbags to be made from heavy thermoplastic (such as .002 to .020 inchesthick) without using a heat resistant coating on the gusset. Because ofthe nature of the heavy thermoplastic, the side edges of the bags 116are separately welded by jaws 68 and 70. As a result thereof, thecorners at the intersection of welds 37 and 67, for example, are verystrong as compared with prior arrangements wherein this intersection isthe weakest portion of the bag.

Referring to FIGS. 1014, there is illustrated another embodiment of thepresent invention designated generally as 10. Apparatus 10 is identicalwith apparatus 10 except as will be made clear hereinafter. ln apparatus10', the notch welders weld and cut the notches before the material istransported to the next station at which station the transverse cuttingand welding will take place. Corresponding elements in apparatus 10 and10 are provided with corresponding primed numerals.

As shown more clearly in FIG. 10, the notch welder 34' includes a Vshaped seam welder 52' which is flattened at its apex and comprised ofwelding jaws 132 and 134. The anvil 42' is water-cooled and is providedwith anvil jaws 136 and 138 which cooperate with jaws 132 and 134. Ablade 140 is provided between the jaws 136 and 138.

The notch welder 34' also includes a generally V-shaped seam welder 58'having jaws 142 and 144 adapted to cooperate with jaws 146 and 148 onthe juxtaposed mating anvil. A knife blade 150 is carried betweenthejaws 146 and 148.

As shown more clearly in FIG. 12, the notch welder 34 applies a pair ofspaced parallel seam welds 37' and 37" which converge toward mating seamwelds 39' and 39" to intersect the seam welds 41' and 41". The blade 140cuts the notch 96' along the line 152 disposed between the seam weldsdefining the notch. Means such as the above-described shuttle isprovided to remove the tab 96 before the material is moved to the nextstation. At the next station, the material is cut and weldedtransversely at a location corresponding generally to the apex of theV-shaped notch. See FIGS. 13 and 14. The heated welding head comprisesjaws 152 and 154 depending from the support 66'.

An anvil is provided having anvil jaws 156 and 158 for cooperation withjaws 152 and 154. A blade 160 is supported in a carrier 162 between thejaws 156 and 158. Carrier 162, and the corresponding carrier for theabove-described blades, are preferably made from a heat-insulatingmaterial. Blade 160 cuts the material transversely along line 73'. Jaws152 and 154 seam weld the material along seam welds 87' and 89respectively.

The present invention may be embodied in other specific forms withoutdeparting from the spirit or essential attributes thereof and,accordingly, reference should be made to the appended claims, ratherthan to the foregoing specification as indicating the scope of theinvention.

lclaim:

1. A method of making bags of thermoplastic material comprising thesteps of forming a gusset along a fold line of a web of thermoplasticmaterial, separating the gusset into top and bottom sections, separatelywelding V-shaped notches in the top and bottom sections at a firststation, moving the web to a second station, providing a pair oftransverse spaced parallel seam welds at a second station in a mannerwhereby the seam welds intersect the apex portion of the notches,cutting along the V-shaped notches to define tabs which are discarded asscrap, and cutting between the transverse parallel seam welds to definediscrete bags.

2. A method in accordance with claim 1 including the step of providing aslit at the first station within the notch adjacent the apex of thenotch in both of the top and bottom sections.

3. A method in accordance with claim 2 wherein said cutting stepincludes using three disconnected blades, each of which intersects aportion of the slit.

E t. A method in accordance with claim 1 wherein said step of weldingnotches includes positioning thetop and bottom seccomprising means forproviding a gusset along'a fold line of thermoplastic material, an anvilhaving converging surfaces for disposition between top and bottomsections of the gusset, a notch welder means juxtaposed to said'surfacesfor intermittently welding generally V-shaped notches at spaced pointsalong the gusset sections, and a welder-cutter downstream from saidnotch welder, said welder-cutter including spaced parallel jaws forproviding seam welds transversely of the thermoplastic material andextending for an apex portion of the notches, said welder-cutterincluding a blade means for cutting the material between the weldsformed by the jaws.

7. Apparatus in accordance with claim 6 wherein said blade means iscomprised of three disconnected blades mounted on an anvil below theplane of the thermoplastic material.

8. Apparatus in accordance with claim 6 wherein said notch welder meansincludes a pair of V-shaped welding jaws mounted for movement toward andaway from the anvil, said anvil having mating jaws, each anvil jawincluding a knife blade for cutting each section of the gusset.

9. Apparatus in accordance with claim8 wherein each anvil blade isV-shaped

1. A method of making bags of thermoplastic material comprising the steps of forming a gusset along a fold line of a web of thermoplastic material, separating the gusset into top and bottom sections, separately welding V-shaped notches in the top and bottom sections at a first station, moving the web to a second station, providing a pair of transverse spaced parallel seam welds at a second station in a manner whereby the seam welds intersect the apex portion of the notches, cutting along the Vshaped notches to define tabs which are discarded as scrap, and cutting between the transverse parallel seam welds to define discrete bags.
 2. A method in accordance with claim 1 including the step of providing a slit at the first station within the notch adjacent the apex of the notch in both of the top and bottom sections.
 3. A method in accordance with claim 2 wherein said cutting step includes using three disconnected blades, each of which intersects a portion of the slit.
 4. A method in accordance with claim 1 wherein said step of welding notches includes positioning the top and bottom sections adjacent to one of the converging surfaces of a generally V-shaped anvil.
 5. A method in accordance with claim 2 wherein said step of welding notches includes providing a generally V-shaped notch which is truncated generally parallel to but spaced from the slit.
 6. Apparatus for making bags of thermoplastic material comprising means for providing a gusset along a fold line of thermoplastic material, an anvil having converging surfaces for disposition between top and bottom sections of the gusset, a notch welder means juxtaposed to said surfaces for intermittently welding generally V-shaped notches at spaced points along the gusset sections, and a welder-cutter downstream from said notch welder, said welder-cutter including spaced parallel jaws for providing seam welds transversely of the thermoplastic material and extending for an apex portion of the notches, said welder-cutter including a blade means for cutting the material between the welds formed by the jaws.
 7. Apparatus in accordance with claim 6 wherein said blade means is comprised of three disconnected blades mounted on an anvil below the plane of the thermoplastic material.
 8. Apparatus in accordance with claim 6 wherein said notch welder means includes a pair of V-shaped welding jaws mounted for movement toward and away from the anvil, said anvil having mating jaws, each anvil jaw including a knife blade for cutting each section of the gusset.
 9. Apparatus in accordance with claim 8 wherein each anvil blade is V-shaped 